MJD OILFIELD SERVICES LIMITED Doc. n.

MJD-QM-PR-022

Rev. 00 Date: 17/01/2016

Document Title: WORK METHOD STATEMENT FOR
PRE-COMISSIONING OPERATIONS
Page. 1 of 19

WORK PROCEDURE FOR

PRE-COMMISSIONING OPERATION.

Description of
Date Rev. Prepared Checked A p p r o ve d
R e vi s i o n

ISSUED FOR
15/03/2015 01 ABEGUNDE A. EZEIKE E. F A MI L U S I O .
I MP L E ME N T A TI O N
 REVISION/CHANGE TRACK RECORD

Section
Revision Revision Description
para/location

MJD Method Statement for Pressure Test of

Mainline (MJD/P0006-Q-MSPC-003_11) was
reviewed to W ork Procedure for Pre-
01 ALL commissioning (MJD-QM-PR-XXX Rev 01).
This was done to accommodate the
requirements of ISO 9001 : 2008 Standard
(Quality Management Systems)
TABLE OF CONTENTS

REVISION/CHANGE TRACK RECORD

1 GENERAL INTRODUCTION

2 OBJECTIVE

3 SUMMARY NARRATIVE

3.1 PRE-CONDITIONS

3.2 CLIENT’S RESPONSIBILITY

3.3 CONTRACTOR’S RESPONSIBILITY

4 PERSONNEL

5 EQUIPMENT

6 PROCEDURE

6.1 GENERAL

6.2 CLEANING, GAUGING AND FILLING

6.3 PRESSURISATION, STABILISATION AND HOLD POINT

6.4 ACCEPTANCE

6.5 DEPRESSURISATION

6.6 DEW ATERING FOR FILLING W ITH INHIBITED W ATER

6.7 FILLING W ITH INHIBITED W ATER

7 S AFETY CONSIDERATIONS
1 GENERAL INTRODUCTION

The objective of this document is to provide a manual that gives

some information and guidance, from a process engineerin g
perspective, on pre -commissioning and commissioning operations to
be executed as part of the act ivities to complete the Project.

SCOPE

This document outlines the method for executing the pressure test
of mainline in line with the scope of work so assigned.

2 OBJECTIVES

This is one of the MJD documents that are aiming at provi ding
assurance to that construction activities on the Project are being
conducted as required by the pressure test of mainline specification
and manufacturer procedures while observing the safety precaution
that will bring about safe work operation.

Some Specific Objectives include:

 Implement commitment to Safety;

 Implement commitment to Total Quality M anagement;
 Implement commitment to quali ty of the construction activity;
 Manage and provide oversight to ensure installation and
related quality control h ave been adequately addressed by
specifications, drawings, and procedures;
 Manage and provide supervision and control on the
engagement of key personnel whose involvements have impact
on product realisation.
 Record installation test activities

3 SUMMARY NAR RATIVE

Prepare a programme for the cleaning, gauge pigging and pressurisation
of the mainline.

In line with the programme, Drive a traceable swabbing pig through the
line with a 40 mesh SW G 33 filtered brackish water. Use the same
filtered brackish water to drive a bi -directional pig fitted with 2 sets of
gauging, guiding and sealing discs through the line. Examine the
gauging discs for damage. If the type and location of the defect in the
pipeline can be determined from the gauging disc cut -out and replaces
the defective pipeline section. Otherwise run a calliper pig through the
line to measure the pipeline bore and the distance travelled.

Slowly drive two bi -directional cleaning pigs through the line with water
ahead of the first pig and water in -between the two pigs to ensure
removal of all air. Blind flange the open ends of the line when the pigs
have been received.

Pressurise the line at the maximum rate of 20 bar/hour to 30 bar and

hold for 2 hr. to ascertain the quantity of air in the line. Incr ease the
pressure to 105 bar and hold for 30 min. Check for leaks at flanges.
Tighten flanges if any leak is detected. If leak is at a weld, cut out and
replace defective section. Pressurise to 150 bar at 20 bar/hour

and hold for 2 hr. to allow for stab ilisation. Reduce pressure to 75 bars
at the rate of 20 bar/hour and hold for 30 min. Pressurise to the 150 bar.
Hold the pressure for 24 hours.

W hen the 24-hour hold period has been found acceptable, depressurise
at 1 bar/min. to 140 bar and subsequentl y at 2 bar/min to +1 bar.

Air drives a bi-directional high seal air and fresh water pig train through
the line to dewater the line. From the break tank, slowly fill the line with
water and corrosion inhibitor and dye through a chemical injection pump
to a pressure of 7 bar and leave in that state.

3.1 PRE-CONDITION
3.1.1 CLIENT RESPONSIBILITY

The client shall issue and approve the following before

pressure testing of the pipeline section commences.

 Biocide and Oxygen Scavenger (Corrosion

Inhibitor)

 Issue permit-to-work (PTW )

3.1.2 CONTRACTOR RESPONSIBILITY

 The contractor shall be responsible for the

following prior to the commencement of
pressure testing.

 Completion of warning signs fabrication.

 Temporarily fabricated pig launchers and

receivers

 Stuck pig retrieval method

 Proposed test chart and report formats

 Proposed Test Pressure

 Location of the Test Pump, Relief Valves and

Test Barge

 Method of disposal of inhibited water

 Fabrication of test head

 Calibration of Test Equipment

4 PERSONNEL

S/N Personnel No. Function

1 Test Engineer 1 Directs the operations

2 Technicians 2 Ensures all equipment are in good working

condition
3 Test Equip. 2
Operators Operates the test equipment
4 1
Crane Operator Provides lifting services
5 1
Tally Clerk Records all test data
6 4
Helpers Labour for bolting and removal of test head
etc.
 5 EQUIPMENT

S/n Equipment Qty. Function

1 Crane 1 Provides lifting services

2 Pressure Pump As To pressurise pipeline

3 Fill Pump Reqd To fill pipeline with water

4 Chemical injectn. Pump 1 To fill pipeline with corrosion inhibitor

To drive pigs during dewatering

5 Air Compressor 1 To introduce water, pigs, inhibitor &

receive pigs. To isolate test pump.
6 Test Manifold / Pig 1
Trap

Pressure Recorder Continuous pressure measuring /

7 1
recording at the test head

Continuous temp. measuring / recording

Temperature Recorder
8 2
at the test head

For constant water supply and surge

Break Tank
9 2 reduction to pumps

Pressure Probe
Deadweight Tester
10 1 Dewpoints for air & Nitrogen used for
Dewpoint Meter pigging during dewate ring & drying
11

Flowmeter/Recorder To measure the volume of water pumped

12 As
LP, HP & Diffr. Gauges Reqd into the line

Filter Unit To measure pressure and temperature

13
 Filling Pigs 1 To remove dirt from entering the line

14 Cleaning Pigs To remove air during water filling

15 Gauging Pigs As To remove construction debris and mill

scale
16 Reqd
To ensure that there is no major d amage
17 Calliper Pigs
inside the line
As Reqd
To check for pipe out of roundness
18 As Reqd

As Reqd

As Reqd

As Reqd

As Reqd
 6 PROCEDURE

6.1 GENERAL

S/N Description Action Party

Schedule and Test Isometrics

Prepare testing isometrics for each line. Test Engineer

Develop a schedule for the testing of each

section and issue it to the client two weeks
before pressure test commences.
All Test Engineer
chemicals to be used in the pre -treatment of
test water and their dosing rates shall also be
specified in the schedule.
Materials
Confirm that the pipeline minimum wall
Test Engineer,
thickness in the design packa ge remains
Fitter, W elder
unchanged, otherwise determine the test
pressure using the equation
where P = test pressure, t = nominal
thickness of pipe in mm., t 0 = maximum –ve
tolerance for pipewall in mm., D = outside
diameter of pipe in mm and f y = SMYS N/mm 2
(Specified Minimum Yield Stress).
Fabricate test manifolds. Radiograph all
welds and prepare Radiographic Inspection
Test Engineer,
Reports.
Third Party
Laboratory
Conduct a laboratory analysis of the brackish
and Project Site Flowstation / Sub -base water
to be used for the integrity check. Brackish
water samples shall be taken at ebb tide –
the time when linefill shall occur and when
Spread Chief
 the water salinity is at its minimum level.

Ensure the availability of all equipment,

calibration certificates and record sheets
indicated as attachments to this procedure.

6.2 CLEANING, GAUGING AND FILLING

S/N Description Action Party

1 On completion of all tie -ins, air-drive or Test Engineer,

water a traceable swabbing pig through the Operators, Helpers
line at 7 bar into a pig trap.

Test Engineer,
2 Air-drive brush pigs through the line into a
Operators, Helpers
pig trap at 7 bar until the line is clean.

Insert two swabbing pigs into the line and Test Engineer,
3 push the pigs through the line with water at a Operators, Helpers
speed of 1m/s.

If a pig gets stuck in (1), (2) or (3) above, Test Engineer,

4
locate the traceable pig(s) and replace the Operators, Fitter,

defective section and re -commence activities W elder, Helpers

from that stage.

W ater-drive a gauging -pig through the line to

5 Test Engineer,
ensure that there is no major damage to the
Operators, Helpers
pipeline during construction. The pump shall
be fitted with a metering device to quantif y
the amount of water pumped into the line and
ascertain the location of the plate in the
 event of a stuc k pig.

Test Engineer
Inspect the plate for undue deformation.
6

7 Re-run the pig as many times as necessary Test Engineer,

until it emerges with the gauging plate in an Operators, Helpers
acceptable condition.

Test Engineer,
In the event of persistent damage to the pipe, Operators, Fitter,
8 run a calliper pig through the line. The pig W elder, Helpers
shall be propelled by water at a speed of
1m/s. In the event of a stuck pig or serious
damage to the line, the defective section
should be cut out and replaced. Re -
commence activities from (4).

Test Engineer,
W ater-drive a calliper pig through the line at Operators, Fitter,

9 1m/s. to prove the bore of the pipeline. In the W elder, Helpers

event of a stuck pig or unacceptable out -of-
roundness, cut out and replace the defective
section. Re -commence activities from (4).

Test Engineer,
Fill the line with a 40 mesh SW G 33 filtered
Operators, Helpers,
10 brackish water.

6.3 PRESSURISATION, STABILISATION AND HOLD POINT

S/N Description Action Party

1 Connect the pressure/temperature Test Engineer, Operators,

recorders and gauges to the pressure test
 pump.

2 Raise the pressure at a constant rate of 1 Test Engineer, Operators,

bar/min. to 35bar while simultaneously Helpers
plotting the graph of pressure (on Y -axis)
against water input volume at 1 ba r
intervals.

Test Engineer, Operators,

3 Determine the air content in the pipeline
Helpers
from a straight line drawn through the P -V
curve and cutting an intercept off the input
volume axis at zero pressure.

4
If the air content exceeds 0.5% of the Test Engineer, Operators,
pipeline volume, then the line shall be
Helpers
pigged further by inserting two swabbing
pigs into the line and pushing the pigs
through the line with water at a speed of
1m/s. Otherwise, the pressure shall be
held at 35 bar for 30 min. and a leak
check carried out.

Test Engineer, Operators,

5 Tighten bolts as necessary, if a l eak
Fitter, W elder, Helpers
occurs at flanged joints. If the leak occurs
on a weld or on the pipe, drain the water
from the line, cut out and replace the
defective section. Commence pressure
test again from (1).

6
Test Engineer, Operators,
 Increase the pressure at a constant rate of Helpers
1 bar/min. to 70 ba r and hold the pressure
for another 30 minutes.
Test Engineer, Operators,
Fitter, W elder, Helpers
7
Carry out a leak check. Tighten bolts as
necessary, if a leak occurs at flanged
joints. If the leak occurs on a weld or on
the pipe, drain the water from the line, cut
out and replace the defective section .
Commence pressure test again from (1).
Test Engineer, Operators,

Helpers
8
Increase pressure to 150 bar at 0.5
bar/min and hold for 2 hours.
Test Engineer, Operators,
Helpers
9 Reduce pressure to 70 bar at a rate of
2bar/min.
Test Engineer, Operators,
Helpers
10 Carry out a leak check. Tighten bolts as
necessary, if a leak occurs at flanged
joints. If the leak occurs on a weld or on
the pipe, drain the water from the line, cut
out and replace the defective section.
Test Engineer, Operators,

Helpers
11 Commence pressure test again from (1).

Test Engineer, Operators,

12 Raise the pressure at the rate of 1
Helpers
bar/min. to 150 bar.
Test Engineer, Operators,

Helpers
13 Record ambient temperature and
temperature of the test water. Test Engineer, Operators,

Helpers

14 Disconnect test pump, plug the connection

to the test header and insert a new chart
into the pressure/temperature recorder.

Record the pressure at hourly intervals for

24 hours with a dead -weight tester.

6.4 ACCEPTANCE

S/N Description Action Party

1 All plots, charts, records, calculations and Test Engineer

test results shall be approved and signed by
the sub-contractor – if any, MJD and CLIENT
in that order. Original copies of all records
shall be stored an d issued to CLIENT at the
end of the contract as part of the pipeline as -
built information.
2 Test Engineer
Interpret the plots, charts, records and
calculations. Loss of pressure that cannot be
accounted for by a temperature variation or
air absorption shall be regarde d as a failure
and the leakage point located, cut out and
3 Test Engineer,
replaced.
Operators,
Repeat the pressurisation, stabilisation and Helpers
hold period procedure as indicated in 6.3
above after the replacement.
 6.5 DEPRESSURISATION

S/N Description Action Party

1 Open the pressure let -down valves slowly to Test Engineer,

depressurise the line at the rate 1bar/min. – Operators, Helpers
so that vibration is not generated in the pipe
work – to 140 bars.

Continue depressurisation at 2bar/ min. to a

Test Engineer,
2 hydrostatic head of +1 bar so that air does
Operators, Helpers
not enter into the pipeline.

6.6 DEW ATERING FOR FILLING W ITH INHIBITED W ATER

S/N Description Action Party

1 Set up a pig train by inserting one high seal Test Engineer,

pig into the line. Operators,
Helpers

Pump water of 4% the pipeline volume into the

2
line. Test Engineer,
Operators,
Helpers

3
Insert another high seal pig into the line and
Test Engineer,
follow it with water of 4% the pipeline volume.
Operators,
Helpers
4
Insert a third high seal pig an d air drive the
train about 300m. Along the line.
Test Engineer,
 Operators,

5 Insert the fourth pig into the line and propel Helpers
the train the entire length of the line at 1m/s.

Test Engineer,

Receive the test water, the batch of fresh Operators,

6
water and pigs into the temporary pig receiver Helpers
and take records of the salt content of the salt
and fresh water received. Test Engineer,
Operators,
Helpers

6.7 FILLING W ITH INHIBITED W ATER

S/N Description Action Party

1 Fill the line with a mesh SW G 33 filtered Test Engineer,

brackish water. Operators,
Helpers

2
Blind flange both ends of the line and leave in Test Engineer,
Operators,
that state
Helpers

7 SAFETY CONSIDERATIONS
Emergency Plan
An emergency plan shall be set up in the construction CASHES
plan to cater for pipeline leaks and site access during pressure
testing. The plan should have methods to access the list of
personnel and equipment on site. It should also contain the
telephone numbers of relevant authorities such as MJD base
location, CLIENT, Police and MJD Retainership clinic.
Notification of Relevant Authorities
Notification shall be given to the relevant Federal, State , Local
Authorities and third party service providers of the date, time and
duration of the test.

Warning Signs
Notices in English and local languages bearing 'KEEP AW AY -
PIPELINE UNDER TEST shall be displayed along the R.O.W .,
river crossings and facil ities within 50m of the pipeline under test.

Security / Safety Patrols

Potentially hazardous areas shall be regularly patrolled.

Hazardous Area
All staff must keep a minimum distance of 20m away from the test
head during pressurizing. The test pump, sh all be located away
from public facilities, unauthorized personnel shall be barred from
the test sites.

Communication
The test cabin, the two ends of the line and the patrol teams shall
be provided with a radio communication.

Test Equipment
All equipment shall be protected against lightning and static
electricity. Only rigid pressure hoses shall be permitted in the test
cabin. Hazard tapes shall delineate the locations of test
equipment. Blind flanged pipe ends shall be shielded away from
personnel by sand bagging or other concrete wall. Pressure let -
down valves shall be opened slowly when depressurizing to
eliminate or reduce vibration in the pipework. Any fitting attached
to this valve should be welded, braced or tied down.

Corrosion Inhibitors and Dyes

Manufacturers safety recommendations concerning storage,
handling and disposal shall strictly be adhered to. These properly
marked chemicals shall be kept away from heat and flames. At
least one eyewash station shall be stained at the site.